Special fabrication of duvet covers, pillowcases, shams, and comforters

ABSTRACT

An exemplary method for fabricating duvets, shams, or pillowcases comprises: providing first squared fabric leftover pieces of a first color; providing second squared fabric leftover pieces of a second contrasting color equal to the first pieces; stitching together the leftover pieces arranged in a checker pattern, wherein each first square is adjacent to second squares and vice-versa, forming a top and a bottom joint sheets substantially equal and rectangular, both having two longitudinal sides and transversal sides; superimposing the top sheet on the bottom sheet, stitching them together along the longitudinal sides and one transversal side by a sewing machine, thereby coupling them. A comforter can be made of one top joint sheet (produced by the above method), one heat insulation layer, and one regular bottom sheet. A method modification includes arranging a joint sheet from strips; wherein each strip differs from its adjacent strip or strips by contrasting colors.

TECHNICAL FIELD

The present invention relates to bed coverings, specifically to duvet covers, pillowcases, shams, comforters, and methods for making such bed coverings.

BACKGROUND OF THE INVENTION

Prior art describes several methods of producing duvet covers. A typical method includes a step of cutting a substantially rectangular piece of fabric from a continuous roll. This piece of fabric has two longitudinal edges and two transverse edges, wherein the length of the longitudinal edges is substantially double the length of the longitudinal edges of the duvet cover to be produced. The next steps include hemming of the transverse edges; and folding the length of fabric to form a folded edge, in such a way that the two opposing transverse edges come to lie against one another, thereby forming the duvet cover, wherein said duvet cover is inside out, i.e. the side which will finally be on the inside is now on the outside. The next step is provided in this position, wherein the superimposed areas of the two longitudinal edges are sewn together by seams. Then typically buttons are fixed to one hem and buttonholes matching the buttons are made in the opposing hem. The next step is reversing the duvet cover so that its inside is turned to the outside and the seams at the longitudinal edges become hidden from the consumer inside the duvet. Finally, the duvet cover is folded and packaged.

Another method of making fabric covers is disclosed in U.S. Pat. No. 6,173,667. It's described as follows: “The method according to the invention for producing a fabric cover from a substantially rectangular or square length of fabric with two longitudinal edges and two transverse edges comprises the following stages: First of all, at least one strip of hook-and-loop tape is attached, in particular, sewn, to the two opposing transverse edges of the length of fabric in such a way that the respective functionally complementary parts each lie substantially opposite each other with respect to the central transverse axis of the length of fabric. The hook and-loop tape may be attached fundamentally in any desired manner continuously over the entire transverse edge or only in strips. The length of fabric is then folded about the central transverse axis, which becomes a fold axis, in such a way that the two opposing transverse edges come to lie against one another, the parts of the hook-and-loop tape simultaneously forming the hook-and-loop fastening. Thus, the length of fabric takes on the external form of the fabric cover to be produced, wherein folding may preferably be effected such that, in the case of fabrics with two different sides, for example printed fabrics, the side which will ultimately be the outside of the fabric cover is already on the outside. To secure the layers of fabric in the desired form, the superimposed areas of each longitudinal edge are sewn together by means of an ornamental seam, whereby a fabric cover is formed which is closed on three sides and may be fastened and opened on one side by a hook-and-loop fastener. The ornamental seam may be produced using, for example, tight whipstitching or a pearl-edged seam. Since the two longitudinal edges are sewn together with an ornamental seam, reversing of the fabric cover after sewing together may be dispensed with. The ornamental seam remains visible on the outside of the fabric cover and may be used as part of the design, for example by using a contrasting color or the like.”

All the existing methods of making duvet covers, shams, and pillowcases, known to applicant, utilize a first step of cutting a substantially rectangular piece of fabric from a continuous roll. This often drives up the price of the duvet cover, especially when expensive natural fabrics are used in the production of the duvet. On the other hand, there is often a lot of small pieces (leftovers) of fabric produced as a result of fabrication of other products. The leftovers are inexpensive, and are frequently recycled, which requires additional facilities, power, and labor. The leftovers can be used in production of duvets, comforters, shams, pillowcases, etc. The problem with such utilization however exists in that the aesthetic look of so made articles is generally not sufficiently neat to satisfy most consumers. The reason of the unsatisfactory look is that the stitches between the leftover pieces are typically noticeable, which most of the customers don't like.

BRIEF SUMMARY OF THE INVENTION

The purpose of the invention is production of inexpensive and aesthetically acceptable bed coverings based on the inventive method of fabricating such coverings from leftovers. The present invention describes bed coverings, such as duvet covers, comforter sets, shams, pillowcases, etc., and a method for producing thereof from leftover pieces of fabric, while making the stitches between the pieces substantially unnoticeable through the use of a checker or similar pattern for arrangement of the leftover pieces. In the other words, the method allows for a patchwork sheet of fabric leftovers to imitate the look of a whole piece of fabric that could have been produced with a checker or similar pattern, which adds consumer value to the bed coverings fabricated from such patchwork sheets, and at the same time allows to keep lower prices of the bed coverings.

An exemplary form of the inventive method for fabrication of a duvet cover comprises the steps of (a) providing a first plurality of substantially uniform leftover pieces of fabric in the shape of a square of a first color (preferably a lighter color); (b) providing a second plurality of substantially uniform leftover pieces of fabric in the shape of a square of a second color contrasting to the first color (preferably a darker color), wherein the side of the squares of the second plurality is substantially equal to the side of the squares of the first plurality; (c) stitching together the squares of the first and the second pluralities so that forming two substantially equal rectangularjoint sheets (a top joint sheet and a bottom joint sheet), both having a checker pattern, wherein each square of the first plurality is adjacent to squares of the second plurality and vice-versa, the top joint sheet and the bottom joint sheet each have two parallel longitudinal sides and two parallel transversal sides; (d) superimposing the top sheet on the bottom sheet, and providing seams along the longitudinal sides of the joint sheets and a seam along one of the transversal sides of the top sheet and the corresponding transversal side of the bottom sheet by means of a sewing machine, thereby attaching the top sheet to the bottom sheet, and making the duvet cover. Buttons/buttonholes, zippers, adhesive tapes, hook-and-loop fasteners, or similar types of conventional locking devices can then be suitably arranged on the unstitched transversal sides (that have no seam) of the joint sheets.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 illustrates an isometric view of an embodiment of two joint sheets made of leftover pieces of a checker design.

FIG. 2 illustrates a way of attachment of the two joint sheets shown on FIG. 1.

Similar reference numerals on the drawings generally refer to the same or similar elements on both figures. A newly introduced numeral in the description is enclosed into parentheses.

A PREFERRED EMBODIMENT OF THE PRESENT INVENTION

While the invention may be susceptible to embodiment in different forms, there is shown in the drawings, and will be described in detail herein, a specific embodiment of the present invention, with the understanding that the present disclosure is to be considered an exemplification of the principles of the invention, and is not intended to limit the invention to that as illustrated and described herein.

An embodiment of the present invention is illustrated on FIG. 1, 2. The inventive duvet, a sham, or a pillowcase, shown on FIG. 2, comprises a top joint sheet (1) and a bottom joint sheet (2), stitched together by seams (30).

The inventive method of fabrication of such duvet, sham, or pillowcase comprises the step of (a) providing a first plurality of substantially uniform leftover pieces of fabric in the shape of a square (10) of a first color (preferably a lighter color) for the top sheet 1, and correspondingly a first plurality of substantially uniform leftover pieces of fabric in the shape of a square (20) of the first color for the bottom sheet 2, wherein the squares 10 and the squares 20 are substantially equal.

The inventive method of fabrication of the duvet, sham, or pillowcase comprises the step of (b) providing a second plurality of substantially uniform leftover pieces of fabric in the shape of a square (11) of a second color contrasting to the first color (preferably a darker color) for the top sheet 1, and correspondingly a second plurality of substantially uniform leftover pieces of fabric in the shape of a square (21) of the second color for the bottom sheet 2, wherein the squares 11 and the squares 21 are substantially equal. Also, the squares 10 are substantially equal to the squares 11, and the squares 20 are substantially equal to the squares 21. In other embodiments, the squares 10 and 20, and the squares 11 and 21 may be made unequal.

The inventive method of fabrication of the duvet, sham, or pillowcase comprises the step of (c) stitching together the squares 10 and 11, and the squares 20 and 21, so that forming said two substantially equal rectangular joint sheets: the top sheet 1 and the bottom sheet 2, both having a checker pattern, wherein each square 10 (or 20) is adjacent to squares 11 (or respectively to 21) and vice-versa. The sheet 1 has two parallel longitudinal sides (14) and (16), and two parallel transversal sides (15) and (17). The sheet 2 has two parallel longitudinal sides (24) and (26), and two parallel transversal sides (25) and (27). The stitching is provided by transversal seams (12) and longitudinal seams (13) for the sheet 1, and correspondingly by transversal seams (22) and longitudinal seams (23) for the sheet 2, shown on FIG. 1 by waved lines. The seams 12, 13, 21, and 22 can be performed by a conventional sewing machine.

The inventive method of fabrication of the duvet, sham, or pillowcase comprises the step of (d) superimposing the top sheet I on the bottom sheet 2, and providing seams 30 along the transversal side 17 and 27 coupling them together, and seams 30 along the longitudinal sides 14 and 24, and along the longitudinal sides 16 and 26, respectively coupling them together. The seams 30 are performed by means of a sewing machine, thereby attaching the top sheet I to the bottom sheet 2, and thereby forming the duvet cover, sham, or pillowcase, illustrated on FIG. 2.

The inventive method of fabrication of the duvet or pillowcase may comprise an additional step of (e) arranging at least one of the following: buttons/buttonholes, zippers, adhesive tapes, hook-and-loop fasteners, or similar types of conventional locking devices on the unstitched transversal sides 15 and 25 (that have no seam, as depicted on FIG. 2) of the joint sheets 1 and 2 respectively.

In other embodiments, the seams 12, 13, 22, 23, and 30 can be made by equipment another than sewing machines depending on the type of fabric, including glue, applying ultrasound, heat, or other physical fields.

A similar method can be used for fabricating comforters. For example, a comforter (not illustrated) can comprise the top joint sheet similar to the sheet 1 (as shown on FIG. 1, 2), a polyester (or made of another heat insulating material) layer, and a regular bottom sheet (i.e. made of a whole piece of fabric) stitched together, wherein the top sheet is produced using the above described method. The utilization of the top joint sheet allows reducing cost of the comforter comparatively to a comforter that would include a regular top sheet and a regular bottom sheet.

A pattern different from the checker pattern (not shown herein) can also be utilized. Such pattern is based on stitching together a plurality of leftover pieces, shaped as strips, preferably elongated rectangulars, positioned in parallel to each other; wherein each strip differs from a strip or strips it's adjacent to by contrasting colors, and each strip is stitched to the adjacent strip or strips by a seam. In this way the leftover strips patchwork forms a joint sheet having a look imitating a whole piece sheet painted with strips of different colors. The inventive method in this modification allows arranging not only two pluralities of one color each, but allows using strips of the joint sheet of a number of different colors, e.g. it may have a “rainbow” pattern. The number of colors is limited by the number of strips of the joint sheet.

Without further analysis, the foregoing will so fully reveal the gist of the present invention that others can, by applying current knowledge, readily adapt it for various applications without omitting features that, from the standpoint of prior art, fairly constitute essential characteristics of the generic or specific aspects of this invention. 

1. A method for fabrication of a duvet cover, sham or pillowcase comprising the steps of (a) providing a first plurality of substantially uniform leftover pieces of fabric, wherein each leftover piece having a shape of a square; each leftover piece of the first plurality having a first color; (b) providing a second plurality of substantially uniform leftover pieces of fabric, wherein each leftover piece having a shape of a square; each leftover piece of the second plurality having a second color contrasting to the first color; leftover pieces of the second plurality equal to leftover pieces of the first plurality; (c) stitching together the leftover pieces of the first and the second pluralities so that forming a top joint sheet, and a bottom joint sheet essentially equal to the top joint sheet; both said joint sheets having a checker pattern, wherein each square of the first plurality adjacent to squares of the second plurality and vice-versa; the top joint sheet and the bottom joint sheet each having two parallel longitudinal sides and two parallel transversal sides; and (d) superimposing the top sheet on the bottom sheet, and providing seams along the longitudinal sides of the joint sheets and a seam along one of the transversal sides of the top sheet and the corresponding transversal side of the bottom sheet, thereby attaching the top sheet to the bottom sheet, and forming said duvet cover, sham, or pillowcase.
 2. The method according to claim 1, wherein the stitching in the step (c) and the providing of seams in the step (d) performed by means of a sewing machine.
 3. The method for fabrication of a duvet cover or pillowcase according to claim 1, further comprising the step of (e) arranging at least one of the following: buttons/buttonholes, zippers, adhesive tapes, hook-and-loop fasteners, or similar types of conventional locking devices on the corresponding unstitched transversal sides of the joint sheets.
 4. A bed covering, substantially a duvet cover, a sham, or a pillowcase, comprising a top joint sheet and a bottom joint sheet, each including a first plurality of substantially uniform leftover pieces of fabric, wherein each leftover piece having a shape of a square; each leftover piece of the first plurality having a first color; a second plurality of substantially uniform leftover pieces of fabric, wherein each leftover piece having a shape of a square; each leftover piece of the second plurality having a second color contrasting to the first color; the size of the squares of the second plurality substantially equal to the size of the squares of the first plurality; the joint sheets having the first plurality leftover pieces stitched to the second plurality leftover pieces according to a checker pattern wherein each first plurality leftover piece adjacent only to second plurality leftover pieces and vice-versa; the joint sheets each having two longitudinal sides and two transversal sides; and the top and the bottom joint sheets stitched together by seams provided along the two longitudinal sides and one transversal side, thereby forming said bed covering.
 5. A comforter comprising a top joint sheet including a first plurality of substantially uniform leftover pieces of fabric, wherein each leftover piece having a shape of a square; each leftover piece of the first plurality having a first color; a second plurality of substantially uniform leftover pieces of fabric, wherein each leftover piece having a shape of a square; each leftover piece of the second plurality having a second color contrasting to the first color; the size of the squares of the second plurality substantially equal to the size of the squares of the first plurality; the top joint sheet having the first plurality leftover pieces stitched to the second plurality leftover pieces according to a pattern wherein each first plurality leftover piece adjacent only to second plurality leftover pieces and vice-versa; a heat insulating layer; and a bottom sheet made of a whole piece of fabric; wherein the top joint sheet, the heat insulating layer, and the bottom sheet stitched together, forming said comforter.
 6. A method for fabrication of a duvet cover, sham or pillowcase comprising the steps of providing a plurality of substantially uniform leftover pieces of fabric, wherein each leftover piece having a shape of a strip; each leftover piece having a color; arranging the leftover pieces in parallel and adjacent to each other, so that any two adjacent leftover pieces differing from each other by contrasting colors; stitching together the leftover pieces so that forming a top joint sheet; providing a bottom joint sheet essentially equal to the top joint sheet; superimposing the top sheet on the bottom sheet; and providing seams along the longitudinal sides of the joint sheets and a seam along one of the transversal sides of the top sheet and the corresponding transversal side of the bottom sheet, thereby attaching the top sheet to the bottom sheet, and forming said duvet cover, sham, or pillowcase. 